Fibrous wall board and process for producing the same



Mar. 6, 1923. 1,447,708

J. H. CAFFREY FIBROUS WALL BOARD AND PWDCESS FOR PRODUCING THE SAME Filed May 17, L920 5 Shams-sheet l INVENTOR Mar. 6, 1923. 1,447,708 J. H. CAFFREY FIBROUS WALL BOARDAND PROCESS FOR PRODUCING THE SAME Filed Ma 17', 1920 5 sheets-sheet 2 a llti Mar. 6, 1923. 1,447,708 J. H. CAFFREY FIBROUS WALL BOARD AND PROCESS FOR PRODUCING THE SAME +1. by Ms xi-Mme Mar. 6, 1923. 1,447,708

J. H- CAFFREY FIBROUS WALL BOARD ANDfPROCESS FOR PRODUCING THE SAME Filed May 1T" 1:20

5 sheets-sheet 4 J iNVEPITOR v 94's i T L hisattornzy,

Mar. 6, 1923. 1,447,708

J. H. CAFFREY FIBROUS WALL BOARD AND PROCESS FOR PRODUCING THE SAME Filed May 17, 1920 5 sheets-sheet 5 5 m m m8 4 45 .5 an 4s 54 4 531 I If Patented Mar. 6, 1923.

PATENT OFFICE.

' IAIES H. CAFFBEYiOF BUFFALO, NEW YORK.

FIBBOUS BOARD AND PROCESS FOR PRODUCING THE SAME.

Application filed Kay 17,

To all whom it may concern:

Be it known that 1, James H. Carrner, a citizen of the United States, resid' at Buffalo, in the county of Erie and tate of New York, have invented certain new and useful Improvements in Fibrous Wall Board and Process for Producing the Same, and I do hereby declare the following to be a full, clear, and exact description of the same, such as will enable others skilled in the art to which it appertains to make and use the same, reference being had to the i accompanying drawings, and to figures of reference marked thereon, which form part of this specification.

Like figures of reference refer to like parts;

This invention relates to wall boards made of fibrous and cementing materials and to apparatuses and processes for producing the same.

The objects of this invention include the production of a wall board made of flax straw or other long fibrous material and a transparent binding cement, having waterproof and fire resisting qualities providing an inexpensive wall board having considerable strength, one which does not require the use of paper or wood pulp in any form in its construction, and one which is perforated for the purpose of keying on a coating of plastic material, as well as one which is preferably fireproof.

A furtherobject is toproduce the perforated holes in a manner to leave the lips of the holes reinforced by the same material, which is crowded in condensed formation at the lips, which serves at the same time to strengthen the wall board about the holes.

Vith these and other objects, my invention resides in the construction of the wall board, one embodiment of which is hereinafter described, the apparatus for making which is illustrated in the drawings, the

operation of the apparatus being explained,

and what I claim is set forth.

In the drawings,

Figure 1 is' a perspective view of a fibrous wall board, embodying my invention, showing perforations therein, as well as a portion of coating thereon.

Figure 2 is an enlarged view of a fragment of the wall board shown in Figure 1,

1920. Serial Io. 381,924.

illustrating the reinforcement of the material at the lips of a hole therein.

Figure 3 is a top plan of the apparatus embodying my invention for producing wall board.

Figure 4 is a side elevation of the apparatus shown in Figure 3.

Figure 5 is a side elevation of the apparatus shown in Figure 3, illustrating the reverse side to that which is shown in Figure 4.

Figure 6 is a longitudinal elevation of the device shown in Figure 3, taken on the line XX thereof. I

Figure 7 is a perspective view of the perforating member equipped with a. series of specially constructed spikes for the purpose.

Figure 8 is an enlar ed horizontal section taken on the line -Y of Figure 3.

' Figure 9 is a plan View of the perforating members of the aparatus, which are shown in section in Figure 8.

' Figure 10 is a sectional elevation taken on the line ZZ of Figure 9.

Figure 11 is a perspective view of the automatically closable stripping blades, used in connection with the spikes of the perforating member which is shown in perspective in Figure 7 F gure 12 is a fragmental vertical section taken onthe line W-W of Figure 11, illustrating the members which actuate the return of the stripping blades to their normal position, for subsequently receiving the piercing spikes.

Figure 13 is a fragmental perspective view of a special form of conveyor used in this ap paratus,

Figure 14 is a perspective view of one of the links forming the sprocket chain of the conveyor'which is shown in Figure 13.

In the figures, referring particularly to Figures 1 and 2, the wall board 1, is shown to be composed of long'fibers 2 matted together, having holes 3, regularly spaced therein, and having the fibers crowded at the lips 4 of the hole 3. This'fibrous material is impregnated with a transparent material, having waterproof and fire resisting qualities, which cementing material is applied in a liquid form, and afterwards solid ifies.

Referring now to the remaining figures,

chronized with'the conveyors to automatically cut off the sheets.

Considering now the specific construction of the apparatus illustrated in the figures,

there are shown mounted upon the frame 5 three brackets numbered 13 in which is journaled the long worm shaft 14, having fixed thereon, at various points the respective worms 15, 16, 17 and 18. The conveyor 6 is moved by meansof the worm 15, meshingwith the hobbed gear 19 which is fixed upon .the conveyor shaft 20, which shaft has also fixed thereon, the sprocket wheels 21 which are in mesh with the chains 22, made up of special links 23 to which are fixed the slats 24'. On top of each of the slats 24at each end thereof, is fixed a curb member-25 having a recessed portion 26 and an extension 27, so formed that when the slats 24 are in horizontal position, the curb members 25 interengage one another, forming a continuous curb, for holding thefibrous material distributed thereon, from falling 0d the edges of the conveyor.

Betweenthe cement feeding device 9, and the conveyor 6, is a narrow table portion 28, which is level with the top surface of the conveyor 6. This table portion 28 is fixed upon the frame 5 A similar table top portion 29 is positioned between the conveyor 7 and cement feeding device 9, and is fixed upon the frame 5, besides being upon a level with the top of the table portion 28. The

cement feeding device 9-has two opposed rollers- 30 and 31, whichare journaled with an extension 5= of the frame 5. Fixed to the shafts 32 and 33 of the respective rollers 30 and 31, are the respective gears 34 and 35 of equal size and in mesh with one another. Fixed at one end of the shaft 33 is the hobbed gear 36, which engages the worm 16 on the shaft 14. The roller 31 revolves within a trough 37, which is shown in section in Figure 6 to contain a liquid cement 38, in which the roller 31 is partly immersed. This liquid is the cementing solution, which is fed up to the under side of fibrous mass forming the body of the wall board 1, when the same comes in contact with thewetted surface of the roller 31. The

trough 37 .is supported upon the frame 5.

The surface of the roller 30 is wetted With mam cs the cementing solution from nozzles 39 fed by a pipe 40, from a source of cementing solution supply. ,Above and below the-table portion-29 are the longitudinal scrapers 41 and 42, which bear against the respective rollers 30 and 31, and which are supported on the framework of the trough 37. These scrapers 41 and 42' are positioned to scrape the surface of the rollers 30'and 31 respec-,

tively, after the same have passed beyond-'75 contact with fibers of the wall board 1 in formation, and their purpose is to keep clean the surfaces of the rollers 3t) and 31.

Considering how the detailed construction .of the piercing device 10, there is shown mounted upon the frame 5, a track 43, made up of rails 44 and 45. A carriage 46 is provided with rollers 47 which engage the track 43. Onelend of the carriage 46 is'providedwith a recess48, which is engaged by the finger 49 of the segmental gear 50, which. gear is journaled at 51 upon, the rail 45.

'Meshing with-the gearsegment 50, is another gear segment 52, fixed to the shaft 53 in the frame 5. The shaft 53 has extensions beyond the opposite side of. the frame 5, and has fixed to it a segmental gear '52 similar to the gear 50 pivoted at 51 toltherai1 44.

The gear 50 has a finger 49 cngaging a recess 48 in the frame 46 in a manner similar to the engagement of the finger 49 with the recess 48 on the opposite side of the anachine. The gear 52 has a-finger 54, upon which is journaled'. the link 55, the opposite end of which is journaled'uponfthe wrist pin 10c 56, of the gear 57 which gear is fixed upon a shaft 58. Thegear 57 is in mesh with an I idler gear 59, pivoted at 60 to the frame 5, and the idler 59 in turn meshes with the ear 61 fixed upon the shaft '62, to which sha is fixed the worm gear 63 in mesh with the worm 17, whereby the; train of gears and shafts just described, get their motion. The opposite end of the conveyor 7 has gears 64 meshing with the chains of the conveyor 7, 11o

fixed upon a shaft 65, journale'd in an extension 5" ,of the frame '5.

The conveyor 8 has a bobbed'-gear;66,. fixed upon the shaft 67 ininesh withthe worm 18. At the opposite end of the con- 5 ve'yor- 8, is the shaft, 68, journaled in the frame 5, as is also the shaft 67. Upon the shaft 68 is fixed a sprocket wheel 69, having in mesh therewith the chain 70, the lower end of which is in mesh with the sprocket wheel 20 71, fixed upon the shaft 72. Referring now to the opposite side of the machine, follow-' ing the shaft 72, there is shown fixed there- 'to, a sprocket wheel 73, .which engages a chain 74, the upper end of which chain en gages a sprocket wheel 75, upon a shaft 76, journaled in the standards 46 of the carriage 46.

Positioned for vertical reciprocation within the carriage 46 is the perforating member cal slots8l and below the same, on the -out- Similar rollers side of the extension 78. 84 journaled upon pins85 are positioned in line with the slots 81 above the same at the upper ends of the extensions 78.

Returning now to the shaft 76, there is shown (particularly in Figure 10) two sets of caiifs '86 engaging the rollers 82, while the cams 87 engage the rollers 84. It will be noticed that the cams 86 have an extended portion 86, while the'cams 87 have a notched portion 87. These cams are so co-ordinated tl1at,the distance between any two points on the respective surfaces, in any axial line to the shaft 76 will be of one length, so as to give an absolute control over the movement of the perforating member 77, in its reciprocation within the guide ways 46 of the carriage 46,, to prevent any lost motion in the same, giving absolute control of the movement so arranged and synchronized as to fulfill the functional movement of the piercing device relative tothe movement of the wall board thereunder, during formation.

The member 77 is provided with a plural- I ity of spikes 88, having tapered-ends, equally spaced in two rows but staggered in the rows. These spikes 88 pass down through holes 89 in a stripping plate 90, which is fixed in the carriage 46. Also fixed in the carriage 46 is a similar stripping plate 91 having a series of holes 91 -with which the spikes 88 register and are in reciprocation. ()n the top of the plate 91 rests a pair of stripping blades 92. These stripping blades are shown in perspective in Figure 11 and in plan in Figure 9. The upper 92 of the stripping blades 92, is formed into broad flat teeth\92", having notches 92 which are positioned to register with one of the rows of spikes 88. At the bottom of the recess between adjacent teeth 92", are notches 92 which register with the other row of spikes 88. The lower 92 of the stripping blades hase broad teeth 92 with notches 92 registering withthe notches 92 of the teeth 92", while there are notches 92- at the bottom of the recesses between adjacent teeth 92 registering with the notches 92 of the teeth 92". The teeth 92" and. 92 overlap one another. The upper blade 92 has end portions-93 which rest upon the top of the end portions 94 of the lower blade 92". Fixed to the end portions 93 are reinforcing strips 95, having conical holes 96, and slotted holes 97 and 98. On the underside of the stripping blade 92 are reinforcing strips 95 fixed thereto. Referring to Figure 12, the reinforcing strip 95 is shown to have a slotted hole 96' opposite the tapered hole 96, of the reinforcing strip 95, and a conical hole 98 opposite the slotted hole 98. There is a slotted hole 97" opposite the slotted hole 97, but positioned in the opposite direction therefrom. Passing up through the holes 97 and 97" is a pin 99, which is anchored in the carriage 46. It will be noticed that the slots 97 and 97" extend in opposite direction to this pin 99, the reason for which will be explained hereinafter. Passing up through the holes 96 and 96 is a pivoted rod 100, journaled at 101 to the screws 102 (see Figure 10), which screws are fixed in the carriage 46. The lower portionof the rod 100 forms a finger 103, which is longenough to engage a pin 44 fixed in a certain position in the rail 44. Passing up through the holes 98 and 98 is the pivoted rod 104, journaled upon the screws 105, fixed in the carriage'46. Connecting the rods 100 and 104 is the tension spring 106, which serves to cause the rods 100 and 104 to throw the reinforcing strips 95 and 95, normally positioned to register as shown in the figures in a closed position against the anchored-pin 99, at the slots 97 and 97* as shown in Figures Y11 and 12, holding the blades 92 and 92 in a position to have the notches 92 and 92 register with one another in a position to form a small 'hole for engaging the point of a spike 88.

Journaled on the shaft 53 is a roller 53, and journaled on the frame 5 of the machine are rollers 107. Passing around the roller 53 and the rollers 107 are the endless belts 108, which pass over in contact with the top of the stripping blades 92 and are positioned between the spikes 88.

Between the conveyor 8 and the piercing device 10 is a set of rollers 109 and 110 posi-' tioned respectively above and below the board in formation. The roller 110 is journaled in an extension 111 of the frame '5, while the roller 109 is journaled in a block 112, positioned in ways 113 and adjustably fixed by'bolts 115.

Referring now to the shearing device 11, in the end of the conveyor 8, and adjacent to the conveyor 12, there is shown in section. in Figure 6, a guide block 116 upon a frame 117., which frame 117 is made integral with the frame 5. Journaled in the frame 117 is the shaft 118, upon which is fixed at each end a cam 119 having a tooth 120 extending beyond its circular surface. Positioned di rectly below the shaft 118, is the shearing blade 121, which is adapted to reciprocate springs 1241, which normally throw the blade 121 upward, bringing the rollers 123 in contact with thecams 119. I The blade 121 is adapted to operate in shearing action against e theushearing1block/125, which is integral with the frame 117 i' There is a sprocket 12 6, fixed upon the shaft 118, whichengages a sprocket chain 127- and passes around a smaller sprocket wheel 128, fixed to the shaft 67, of the conveyor 8. The difference in diameter being such as needed to actuate the shearing blade 121 at the period which iscommensurate with that required for feeding a certain length of board beyond the shearin block 125 to be sheared ofi and droppe upon the conveyor 12.

In operation, assuming that there has been provided a suitable device for spreading the fiber in a uniform layer upon the conveyor 6, although not herein'show'n, this layer of fiber is caused by the conveyor 6 to move on to the narrow table portion 28, and over the same into engagement with the cement feeding device 9, the rollers 30 and 31 of which are [covered with a film of cementing solution, preferably of a transparent cement having waterproof and fireproof qualities and a toughness like glue and fed upon the rollers by the nozzle 39 and the cement in the trough 37. Both the conveyor 6 and the cementing feeding device 9 receive their motionfrom the worm shaft 1 1.- The scrapers 41 and 12 keep the surfaceof the rollers 30 and 31 clean, and prevent the fiber from rolling up onto the rollers. From the rollers 30 and 31, the wetted layer of fiber is pushed over a table portion 29 onto a conveyor 7, which carries it to the holepiercing device 10; the carriage 16 of which, riding upon a track 43, travels forward with the plastic fiberboard during the hole piercing operation and returns for successive hole piercings. This reciprocal traveling of the carriage 16 is caused by the rocking back and forth of the fingers 4:9- and 19* of the gear segments 50 and 50 which engage the notches 48 and l8 of the carriage 46. At the same time, the piercing operation is actuated through the agency of the sprocket chain 71, connected by a train of mechanism with the conveyors, which train of mechanism, includes the shaft 68 of the conveyor 8, the sprocket wheel 69, the chain 70, the sprocket wheel 71, the shaft 72, the sprocket wheel 73, on the opposite side of the ma chine, to which is connected the chain 7d. The chain 71 turns the sprocket wheel 75, fixed uponthe shaft 76. The shaft 76 turns the cams 86 and 87, which give a vertical reciprocating motion to the piercing memher-77. The'shaft 76 is so synchronized in memos from the wall board Lduring the return of the carriage 46, is such as to have piercing actions follow in close enough succession, to have the series of holes formed by the successive piercings, equally-spaced. V r

During tliareciprocation of the spikes 88 of the piercing device 77 the rods 100 and 104, normally drawn together by the spring 106 tend to keep the strips 95 and 95* together with stripping blades 92 and 92 in the normally closed position shown in erspective in Figure 11 and in section in igure 6. Figure 10 illustrates the position of the parts when the' spikes 88 are at their lowest limit of reciprocation. -It will be noticed that the finger 103 of the rod 100 is slightly inclined toward the pin 44*1011 the rail 4 1, although spaced therefrom, and this position which isthat at the mid portion of the carriage 46 in' itsforward travel. As

the carriage 46 continues on 'to keep theother half of the forward motion, the cams make a half turn and the piercing'device 7 7 is raised and held raised until the beginning of the next forward movement of the carriage 46 after its return for such forward movement. As the carriage 46 reaches its 4 the strippinghlades 92 and 92 to become normally closed, if fin any reason the spring 106 is not suficiently strong to perform this function.

' After leaving the piercing device 77, the wall board 1, in a semi-plastic condition with its surface somewhatburred at the holes, is'urged forward by means of the metallic belts 108 and coming in contact with the rollers 109 and 110 the wall board 1, is ironed out, so to speak, and the burrs flattened down at the edges of the holes; The wall board 1, next travels in contact with the conveyor 8, and is fed thereby to the shearing device 11, which being connected with the shaft 106 of the conveyor 8, in the manner above described in connection with the desription of the parts of the shearing device 11, the cam finger 120, causes a downward movement of the shearing blade 121, and in connection with the shearing block 125, a portion'of the oncoming wall board is sheared ofi', suddenly, and droppedv upon the conveyor 12. The blade 121 afterwards remains in the positionshown, until the finger 120 of the cam 119 comes around again and depresses the shearing blade 121, cutting oil the next piece of wall board. The synchronisni of movement of the shearing device 11, is such as to cut off the individual pieces of Wall board in ste is the coating of the fiber above and below with a fluid cementing substance which is absorbed by the fiber. It may not be necessary, under certain circumstances to coat both sides of the fiber. in which case, one or the other parts of the. coating device may be omitted. The next step in the process of forming this wall board, is the carrying of the wetted fiber sheet to a suitable pierc- 'ing device wherein the holes are formed and the sheet is passed on to another device, which tends to restore the roughened surface to a smooth state. The next step is the carrying forward of the board in formation to a suitable shearing device for cutting the continuously formed sheet into individual lengths and further carrying the same away where they may be disposed of. If it is desired to leave the wall board unpierced, then of course, the piercing device and its accompanying ironing out device may be dispensed with. If it is desired to form the holes in the plastic board and leave the'surface roughed as it comes from the piercing device without restoring the surface of the board to an even flatness then, of course, the ironing out device can be dispensed with'.

The length of the conveyor between the cement coating device and the piercing device will depend in a large measure upon the rate of time in which the cement liquid between the fibers becomes sufliciently plastic for the piercing operation, as well as upon the rate at which the conveyor travels.

The board herein describedforms a new article of manufacture and may with suitable devices not here shown, be formed into shingles, slabs and other forms depending upon the purposes of buildin construction for which it may be used. 'I lie purpose of having holes in the board, is to give a keyed formation to any coating material that is spread upon the surface of the finished board, such as is shown in Figure 1, at 1. As modifications of the herein described material, process for making the same, and.

the device in which it is made, may be made without departing from the spirit and scope of my invention involved therein, I do not wish to be confined to the embodiment thereof herein illustrated and described, hence I claim A process of forming wall board from fibrous material consisting in coating a mat comprising a plurality of loose fibers with a cement in liquid form to cause said fibers to adhere to one another, in separating said fibers at predetermined places in said mat to provide openings therethrough, and in applying pressure to said mat to causev a firm adhesion of said fibers and to compact the separated fibers at said openings.

JAMES H. oArFREr. 

